Prediction of dimension error based on the deflection of cutting tool in micro ball-end milling

Micro milling forces can easily induce bending deflection when machining micro complex components, which makes the tool center deviate the desired trajectory and causes dimension error. So this study is mainly focused on analysis of dimension error in micro ball end milling. The analytical predictio...

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Bibliographic Details
Published inInternational journal of advanced manufacturing technology Vol. 93; no. 1-4; pp. 825 - 837
Main Authors Yuan, Meixia, Wang, Xibin, Jiao, Li, Yi, Jie, Liu, Shaonan
Format Journal Article
LanguageEnglish
Published London Springer London 01.10.2017
Springer Nature B.V
Subjects
Ball-end milling
CAE) and Design
Cantilever beams
Computer simulation
Computer-Aided Engineering (CAD
Cutting tools
Deflection
End milling cutters
Engineering
Error analysis
Industrial and Production Engineering
Machining
Mathematical models
Mechanical Engineering
Media Management
Milling (machining)
Numerical integration
Optimization
Original Article
Prediction models
Stainless steels
Workpieces
Dimension error
Bending deflection
Micro milling
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Summary:Micro milling forces can easily induce bending deflection when machining micro complex components, which makes the tool center deviate the desired trajectory and causes dimension error. So this study is mainly focused on analysis of dimension error in micro ball end milling. The analytical prediction model of dimension error is proposed based on the deflection of micro ball-end milling cutter induced by micro milling forces, which referenced to Euler Bernoulli cantilever beam equations. The micro milling forces acting on ball end milling cutter can be acquired by numerical integration. And the proposed models using two-section and three-section cantilever beam equation separately were analyzed by comparison. The proposed machining deflection’s error prediction model is validated by micro ball end mill on stainless steel workpiece. The experimental results show that the model based on three-section cantilever beam equation has a better correlation with the simulation results. The proposed theoretical model offers a basis for controlling machining deflection as well as manufacturing process optimization.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-017-0474-z